Building one-of-a-kind vehicles is a unique process that combines ingenuity, expertise, engineering, organization, and passion among other things to get the job done right. Building a bespoke product, such as a custom Land Rover Defender, Range Rover Classic or Jaguar E-Type means that every day brings new challenges, and opportunities to create something truly special.

ECD Automotive Design has grown into the world leader in restoration and customization of classic Land Rover Defender 110, Defender 90, Range Rover Classic and Jaguar E-Type’s. Looking behind the scenes and seeing these classics transform into a truly state-of-the-art, one-of-a-kind modernized version of what they once were is nothing short of remarkable.

The client journey while working with ECD Automotive Design begins with the design process. This is where the client gets to work with our design team to create their masterpiece via 3-D computer modeling and 4D animation. This is where they can select from over 2 million possible combinations to build a truly unique Defender, Ranger Rover or Jaguar E-Type. It is much more than design, but a menu of options from powertrain, colors, upholstery, exterior and interior features, etc.

The production process is another critical aspect of building one-of-a-kind vehicles. At ECD Automotive Design, each part of the vehicle is carefully engineered, handcrafted, and assembled, ensuring that every detail is perfect for the client’s unique specifications. The craftsmanship involved in this process is truly remarkable, as it involves a prominent level of precision, attention to detail, organization and ability to problem solve as each vehicle is bespoke in nature.

North and South Production Line Overview

ECD currently runs two lines, a North and South line, with plans to introduce a third line, the East line, soon. The north line is solely dedicated to the renovation and customization of classic Land Rover Defender 110’s, Land Rover Defender 90’s and Range Rover Classics. Of the Land Rovers, the approximate breakdown is 90% Defender (2/3 Defender 110 and 1/3 Defender 90) and 10% Range Rover Classic. Of course, this is by client demand, so the breakout is subject to change. Each Defender is subject to 622 build and inspection points during production.

At the time of this article, the north line is producing 64 Defenders per year, while the south line running at 34 vehicles per year is divided between the Jaguar E-Type and two additional new products being introduced this year. Each Jaguar E-Type is subject to 589 build and inspection points during production.

ECD Production:  Bay-by-Bay

Although each vehicle is one-of-a-kind, the build process for each line is well organized into distinct functional bays, after it has gone through the prebuild process and entered the main production line area.

The South line, which produces Jaguar E-Types currently, production time is 21 days and includes the following bays/steps:

1. Pre-Build & Paint
2. Bay 1: Roller Assembly
3. Bay 2: Drivetrain & Electronics
4. Bay 3: Final Assembly & Cosmetics
5. Quality Control and Pre-Ship

For the North line which produces the Defenders and Range Rover Classics, assembly time at each bay includes 4 days. The bay categories are as follows:

1. Prebuild
2. Bay 1: Roller Assembly
3. Bay 2: Drivetrain
4. Bay 3: Body Assembly
5. Bay 4: Electric & Interior
6. Bay 5: Final Assembly
7. Bay 6: Inspection

Prebuild

When the ECD procurement team locates the exact classic Defender, Range Rover, or Jaguar E-Type that the client has requested (model, body style, model year), it arrives at our Kissimmee, Florida location (typically from the UK). The first step before it enters the main production line area is the Prebuild process. This is where the vehicle goes through a tear down process and is prepared to enter the production main lines. Pre-build includes:

1. Tear down of the vehicle to the frame
2. Media blast of the frame
3. Welding/fabrication/refurbishment
4. Chassis is galvanized (Defenders and Range Rover Classics)

Bay 1:  Roller Assembly

The first bay begins with adding the Roller Assembly to the frame. The roller assembly is a vital component as it facilitates the movement of various parts within a vehicle thus helping to optimize their performance. The roller assembly is designed to withstand high levels of stress and wear and is constructed using robust materials to ensure durability and reliability. During this process, the axles are added along with suspension, brakes, and brake lines.

Bay 2:  Drivetrain

Moving to the next bay, the vehicle gets a modern, state-of-the-art drivetrain. Each drivetrain component is selected from a menu of options. Engine choices include gasoline, diesel or electric. During this stage, the transmission, fuel tank and exhaust is also installed

Bay 3:  Body Assembly

At this point, the vehicle has gone through the first paint stage and has its Drivetrain installed, it is ready to add the body assembly. The body assembly includes adding the bulkhead, t-posts, tub (bed), and main body electrical harness. The bulkhead is an important partition between the engine compartment and the passenger portion of the vehicle as it performs several functions from being a barrier to acting as a mounting point for various components such as the dashboard to HVAC, etc. Additionally, the T-posts are added during this stage, adding further structural stability as well as acting as a mounting point for doors, seatbelts, etc. The main electrical harness is added at this point. The next phase introduces customization to the electrical harness.

Bay 4:  Electrical & Interior

As mentioned, the main electrical harness was installed in the previous bay, and at this stage the custom sub-assemblies are intricately installed. This is a detailed process and will be highlighted in a later article. The sub-harnesses address the rear lights, roof lighting and wings as well as other custom requirements.

The interior work at this stage includes soundproofing, adding custom carpet, flooring including wood or any customization per the client requirements. Doors and roof are also added during this stage.

Bay 5:  Final Assembly

At this stage everything begins to visually take shape. In the interior, seats are added along with seatbelts, the dash, HVAC, and infotainment system. The second paint phase happens during this stage as well feeding items such as the roof, window surround and trim pieces to be assembled during this stage. Exterior cosmetic lights are added as well as the roll case, winch accessories and hood during this stage.

Bay 6:  Inspection

Although the final bay is specifically for inspection, this is not the first or only inspection point. Quality inspection occurs through each step of the build process. At each stage, there are several check points that are inspected by the assembler, head of production and the quality control inspector. This is before reaching the Bay 6 inspection stage. Once the vehicle reaches this bay, it sits in front of the leadership’s offices and each technician involved in production is allowed 4 days to fine tune anything before it goes to the final Quality Control Inspector and Pre-ship team.

It's All About the People

ECD Automotive Design is not like any company out there. You may hear companies talk about the importance of their human resources, but ECD walks the walk. The company believes that the technicians are the driving force of the company. Rather than a recruitment strategy, the focus is on the retention of great employees. Training and betterment of the team is encouraged. Empowerment to make decisions and own the process is not only encouraged by leadership but embraced by the team.

Additionally, building cross-functional skillsets across the different product lines are encouraged to not only strengthen the technicians but also to provide a contingency alternative to balance out the lines if needed. ECD enforces a safe working environment by enforcing OSHA standards, keeping up with OSHA training, providing, and enforcing use of Personal Protective Equipment.

The End of the Line

The process involved with building a one-of-a-kind classic Land Rover Defender, Range Rover Classic or Jaguar E-Type provides rewards not only to the client, but also to each person involved in the process. Each technician or person involved in the client’s journey can watch a unique vision come to life from the time it was first dreamed up to the day it drives off with the client.

As part of the customer journey, once the vehicle enters the production lines, the process is captured on a live YouTube feed.  This allows the client to watch their dream come to life while it is happening and also provide complete transparency between ECD and the client.

Seeing a unique vehicle come to life from a simple idea or concept is an exhilarating experience. It's not just about creating something new; it's about pushing the boundaries of what's possible in automotive design and engineering. It’s about seeing someone’s dream come true and each person involved feels so much pride when it all comes together.